Autonomous robot auto-docking and energy management systems and methods

ABSTRACT

A method for energy management in a robotic device includes providing a base station for mating with the robotic device, determining a quantity of energy stored in an energy storage unit of the robotic device, and performing a predetermined task based at least in part on the quantity of energy stored. Also disclosed are systems for emitting avoidance signals to prevent inadvertent contact between the robot and the base station, and systems for emitting homing signals to allow the robotic device to accurately dock with the base station.

This application is a continuation of, and claims priority under 35U.S.C. §120 from, U.S. application Ser. No. 14/475,984, entitled“Autonomous Robot Auto-Docking and Energy Management Systems andMethods,” filed on Sep. 3, 2014, which is a continuation of, and claimspriority under 35 U.S.C. §120 from, U.S. application Ser. No.13/291,633, entitled “Autonomous Robot Auto-Docking and EnergyManagement Systems and Methods,” filed on Nov. 8, 2011, which is acontinuation of, and claims priority under 35 U.S.C. §120 from, U.S.application Ser. No. 11/648,230, entitled “Autonomous Robot Auto-Dockingand Energy Management Systems and Methods,” filed on Dec. 29, 2006,which is a divisional, and claims priority under 35 U.S.C. §120 from,U.S. application Ser. No. 10/762,219, entitled “Autonomous RobotAuto-Docking and Energy Management Systems and Methods,” filed on Jan.21, 2004. The disclosures of each of these prior applications areconsidered part of the disclosure of this application and are herebyincorporated by reference in their entireties.

TECHNICAL FIELD

The present invention relates generally to robotic systems and, morespecifically, to auto-docking and energy management systems forautonomous robots.

BACKGROUND

Automated robots and robotic devices are becoming more prevalent todayand are used to perform tasks traditionally considered mundane,time-consuming, or dangerous. As the programming technology increases,so too does the demand for robotic devices that require a minimum ofhuman interaction for tasks such as robot refueling, testing, andservicing. A goal is a robot that could be configured a single time,which would then operate autonomously, without any need for humanassistance or intervention.

Robotic devices and associated controls, navigational systems, and otherrelated systems moving in this direction are being developed. Forexample, U.S. Pat. No. 6,594,844 discloses a Robot Obstacle DetectionSystem, the disclosure of which is hereby incorporated by reference inits entirety. Additional robot control and navigation systems aredisclosed in U.S. patent application Ser. Nos. 10/167,851, 10/056,804,10/696,456, 10/661,835, and 10/320,729 the disclosures of which arehereby incorporated by reference in their entireties.

Generally, autonomous robotic devices include an n-board power unit(usually a battery) that is recharged at a base or docking station. Thetypes of charging stations and methods used by robots in finding ordocking with them (e.g., radio signals, dead reckoning, ultrasonicbeams, infrared beams coupled with radio signals, etc.) vary greatly inboth effectiveness and application. Wires buried below the surface onwhich the robot operates are common, but are obviously limited inapplication, as it is costly to install guide wires within the floor ofa building or below a road surface. If installed on the surface, theguide wires may be damaged by the robot itself or other traffic.Moreover, the wires need to be moved when the base station is relocated.A base station that emits a beam or beacon to attract the robotic deviceis, therefore, more desirable. Such devices, however, still exhibitnumerous operational limitations.

Base stations that utilize emitted signals often still requireadditional safeguards to ensure proper mating between the robot and basestation and, therefore, safe and effective charging. Some requiremechanical locking devices to prevent dislocation of the robot duringcharging, or other components such raised guiding surfaces to direct therobot into contact with the station. Such components can increase thesize of the base station while decreasing the aesthetics, importantconsiderations for automated robots directed at the consumer market. Anincrease in base station size also typically makes unobtrusive placementin the home more difficult and decreases the floor area available forcleaning. Additionally, existing base stations generally lack theability to protect themselves from contact with the robot duringoperation, increasing the likelihood of damage to either the station orrobot, or dislocation of the base station. Such an unintentionalcollision may require human intervention to reposition the base stationor repair a damaged component.

These limitations are, at present, a hurdle to creating a trulyindependent autonomous robot, free from human interaction. There is,therefore, a need for a robot and base station that can ensure propermating regardless of location of the base station. Moreover, a systemthat can prevent inadvertent dislocation of the base station byeliminating collisions between the station and robot is desirable.

SUMMARY OF THE INVENTION

In one aspect, the invention relates to a method for energy managementin a robotic device, the robotic device including at least one energystorage unit and a signal detector. The method includes the steps of:providing a base station for mating with the robotic device, the basestation having a plurality of signal emitters including a first signalemitter and a second signal emitter; determining a quantity of energystored in the energy storage unit, the quantity characterized at leastby a high energy level and a low energy level; and performing, by therobotic device, a predetermined task based at least in part on thequantity of energy stored. In various embodiments of the foregoingaspect, coulometry or setting a time period are used to determine thequantity of energy stored or task period of the device.

In other embodiments of the foregoing aspect, the step of performing thepredetermined task occurs when the quantity of energy stored exceeds thehigh energy level, the predetermined task including movement of therobotic device away from the base station in response to reception, bythe signal detector, of a base station avoidance signal. Still otherembodiments include the step of returning the robotic device to the basestation in response to reception, by the signal detector, of a basestation homing signal and/or returning the robotic device to the basestation when the quantity of energy stored is less than the high energylevel. In other embodiments of the foregoing aspect, the step ofreturning the robotic device to the base station occurs when thequantity of energy stored is less than the low energy level, and whereinthe predetermined task includes a reduction in energy use by the roboticdevice. Various embodiments further include altering a travelcharacteristic of the robotic device to locate effectively the basestation, charging the device upon contact, and/or resuming thepredetermined or a different task.

In another aspect, the invention relates to a method of docking arobotic device with a base station that has a plurality of signalemitters, including a first signal emitter and a second signal emitter.The method includes the steps of orienting the robotic device inrelation to (i) a first signal transmitted by the first signal emitterand (ii) a second signal transmitted by the second signal emitter, andmaintaining an orientation of the robotic device relative to the firstand second signals as the robotic device approaches to the base station.Certain embodiments of the method of the foregoing aspect include thesteps of detecting, by the robotic device, an overlap between the firstsignal and the second signal; following, by the robotic device, a pathdefined at least in part by the signal overlap; and docking the roboticdevice with the base station. Other related embodiments include reducingthe velocity of the robotic device in the step of following the pathdefined at least in part by the signal overlap.

Various embodiments of the method of the foregoing aspect also include,during the step of docking the robotic device with the base station:detecting, by the robotic device, contact with charging terminals on thebase station, and stopping movement of the robotic device. In someembodiments, contact of one or more on-board tactile sensors can beused, additionally or alternatively, to stop movement of the roboticdevice. Other embodiments include the step of charging fully the roboticdevice and/or charging the robotic device to one of a plurality ofcharging levels. Certain embodiments allow for resumption of thepredetermined task or a new task upon completion of charging.

In another aspect of the invention, the invention relates to anautonomous system including a base station, that includes chargingterminals for contacting external terminals of a robotic device, and afirst signal emitter and a second signal emitter. Certain embodiments ofthe above aspect provide that the first signal emitter transmit a basestation avoidance signal and the second signal emitter transmit a basestation homing signal. In other embodiments, the homing signal is a pairof signals, which can be either the same or different. The pair ofsignals may be emitted by a pair of emitters. In some embodiments, thesignals may overlap, and may be optical signals.

Certain embodiments of the above aspect further include a robotic devicefor performing a predetermined task, the robotic device having at leastone energy storage unit with an external terminal for contacting thecharging terminal, and at least one signal detector. In certainembodiments, the at least one signal detector is adapted to detect atleast one optical signal. The robotic device has, in certainembodiments, the capability to distinguish between the signals generatedby multiple emitters.

Still other aspects of the current invention relate to an energy managerincluding: a robotic device having at least one energy storage unit anda signal detector; a base station for mating with the robotic device,the base station having a plurality of signal emitters including a firstsignal emitter and a second signal emitter; and a processor fordetermining a quantity of energy stored in the energy storage unit.Certain embodiments of the foregoing aspect use coulometry or set a timeperiod to determine the quantity of energy stored or task period of thedevice. In still other embodiments the first signal emitter transmits anavoidance signal, thereby restricting a movement of the robotic deviceto directions away from the base station, and the second signal emittertransmits a homing signal, thereby directing a movement of the roboticdevice to the base station.

Other aspects of the invention relate to a homing system including arobotic device having a signal detector, and a base station having afirst signal emitter and a second signal emitter. Certain embodiments ofthe foregoing aspect overlap signals transmitted by the first signalemitter and the second signal emitter. Still other embodiments furtherinclude charging terminals on the base station, and charging terminalson the robotic device.

An additional aspect of the invention relates to a horning system forbase station including a first signal emitter that transmits a firstsignal projected outward from the first signal emitter, and a secondsignal emitter that transmits a second signal projected outward from thesecond signal emitter, such that the first signal and the second signaloverlap. Another aspect relates to an avoidance system for restricting amovement of at least one of a first device and a second device, theavoidance system including a first device that emits a signal, and asecond device that receives the signal, thereby restricting the movementof at least one of the first device and the second device.

Still another aspect of the invention relates to a base station,including a base plate and a backstop, for a robotic device including:electrical contacts located on a top side of the base plate; a firstsignal emitter located on the backstop wherein a signal transmitted bythe first signal emitter restricts the robotic device from moving withina predetermined distance of the base station; and a second signalemitter and a third signal emitter, wherein a plurality of signalstransmitted by the second signal emitter and the third signal emitterguide at least one electrical contact of the robotic device to contactthe at least one electrical contact of the base station.

Another aspect of the invention relates to a method of charging abattery of a device, the method having the steps of providing low powerto charging terminals of a charger, detecting presence of the device bymonitoring at least one of a predetermined change in and a predeterminedmagnitude of a parameter associated with the charger, and increasingpower to the charging terminals to charge the battery. One embodiment ofthe method of the above aspect further includes the steps of determininga level of charge in the device, and permitting charging of the batteryin the device when the level of charge is below a predeterminedthreshold.

Still another aspect of the invention relates to a system for charging amobile device, the system having: a stationary charger comprising firstcharging terminals, circuitry for detecting presence of the device bymonitoring at least one of a predetermined change in and a predeterminedmagnitude of a parameter associated with the charger, and a mobiledevice having: a battery, and second charging terminals adapted to matewith first charging terminals. Various embodiments of the above aspectinclude systems wherein the circuitry determines a level of charge inthe battery and controls a power level provided to the first chargingterminals. Still other embodiments include systems wherein the circuitryincreases the power level provided to the first charging terminals uponmeasuring a predetermined voltage across the first charging terminalswhen mated with the second charging terminal.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, like reference characters generally refer to the sameparts throughout the different views. The drawings are not necessarilyto scale, emphasis instead generally being placed upon illustrating theprinciples of the invention. In the following description, variousembodiments of the present invention are described with reference to thefollowing drawings, in which:

FIG. 1 is a schematic perspective view a base station in accordance withone embodiment of the invention;

FIG. 2A is a schematic perspective view of an robotic device inaccordance with one embodiment of the invention;

FIG. 2B is a schematic side view of the robotic device of FIG. 2A.

FIG. 3 is a schematic perspective view of a representation of roboticdevice and base station, depicting an avoidance signal in accordancewith one embodiment of the invention transmitted by the base station anddetected by the robotic device;

FIGS. 4A-4C are schematic perspective views of representations of homingsignals in accordance with one embodiment of the invention transmittedby the base station and detected by the robotic device;

FIG. 5 is a schematic perspective view of the robotic device and thebase station in a docking or mating position;

FIGS. 6A-68 are flow charts of avoidance algorithms in accordance withone embodiment of the invention;

FIG. 7 is a flow chart of an energy management algorithm in accordancewith one embodiment of the invention; and

FIG. 8 depicts an embodiment of the charger circuitry schematic inaccordance with one embodiment of the invention.

DETAILED DESCRIPTION

FIG. 1 is a schematic perspective view a base station 10 in accordancewith one embodiment of the invention. The base station 10 includes botha substantially horizontal base plate 12 and a substantially verticalbackstop 14. The base station 10 may be any of a variety of shapes orsizes, providing sufficient space for the desired components andsystems, described below. The base plate 12 is generally parallel to theground surface on which the base station 10 rests, but may have a slightupwards angle directed toward the backstop 14. By minimizing the angleof rise of the base plate 12, the robotic device (FIGS. 2A-2B) mayeasily dock with the station 10. Electrical charging contacts 16 arelocated on a top surface of the base plate 12, allowing them to contactcorresponding contacts (FIG. 2B) on the underside of the robotic device.The contacts 16 or the contacts on the robot may be either fixed orcompliant. In the depicted embodiment, two contacts 16 (one positive,one negative) are utilized to properly detect a completed circuit whenthe robot 40 docks with the base station 10. This circuit recognitionsequence is described in more detail below. In other embodiments,however, a single contact 16 or more than two contacts may be utilized.An additional contact would provide redundancy in the event that one ofthe robot contacts becomes damaged, dirty, or obstructed. This wouldallow the robot to dock and recharge itself properly, even after such anoccurrence. Other embodiments utilize two contacts 16 to charge thebattery and additional contacts to transmit data and information betweenthe devices.

The contacts 16 are sized and positioned to reliably and repeatablycontact the corresponding contacts on the robot. For example, thecontacts 16 may be oversized and/or may extend above the base plate 12,e.g., in a domed shape, to ensure contact with the robot contacts.Alternatively, the contacts 16 may be flush-mounted on a base plate 12with a higher angle of rise or may protrude above a base plate 12 thatis flat or has substantially no rise. Depending on the application, thebase plate 12 angle of rise may vary from 0° to up to 20° and greater.The embodiment depicted in FIG. 1 also includes a depression 26 in thebase plate 12, between the two contacts 16, sized to engage a frontcaster (FIG. 2B) of the robot. The depression 26, in combination withthe configuration of the charging contacts 16, ensures proper alignmentand registration between the charging contacts on both the base station10 and the robot. Alternatively, the depression 26 may contain one ormore of the contacts 16 arranged to mate with one or more correspondingcontacts on the front caster of the robot.

The backstop 14 provides locations for many of the base station 10components. Specifically, in the depicted embodiment, the backstop 14includes a top signal emitter 18, a front signal emitter 20, severalindicator LEDs 22, and an AC plug receptacle 24. The top signal emitter18 generates a first signal, such as an avoidance signal (FIG. 3), in adiffuse region near the base station 10 to prevent generally the robotfrom coming into inadvertent direct contact with the base station 10while performing a task, such as vacuuming. The top signal emitter 18generally utilizes a parabolic reflector to transmit the avoidancesignal. In such an embodiment, the avoidance signal is emitted by asingle LED directed at a lens whose geometry is determined by rotating aparabola about its focus. This parabolic reflector thus projects theavoidance signal 60 out in a 360° pattern, without the necessity ofmultiple emitters. A similar configuration can be employed in thedetector on the robot, with a single receiver used in place of thesingle LED.

While the location of the top signal emitter 18 may vary, locating theemitter 18 on top of the backstop 14 transmits the avoidance signalthrough an uninterrupted 360° field around the base station 10.Alternatively, base stations designed for corner, on-wall, or near-wallinstallation may project the avoidance signal substantially only alongthe unobstructed side. The front signal emitter 20 projects one or moreadditional signals, such as homing beams (FIGS. 4A-4C), to allow therobotic device to orient itself during docking with the base station 10for recharging or during periods of non-use. Naturally, if properlylocated on the base station 10, a single emitter may be used to performthe functions of both emitters 18, 20. Both the avoidance signal andhoming beams described in more detail below.

FIGS. 2A-2B are schematic perspective views of a robotic device, such asan autonomous robot 40 adapted to mate with the base station 10. In thefollowing description of the autonomous robot 40, use of the terminology“forward/fore” refers generally to the primary direction of motion ofthe robot 40, and the terminology fore-aft axis (see referencecharacters “FA” in FIG. 2A) defines the forward direction of motion(indicated by arrowhead of the fore-aft axis FA), which is coincidentwith the fore-aft diameter of the robot 40.

In the embodiment depicted, the housing infrastructure 42 of the robot40 includes a chassis 44, a cover 46, and a displaceable bumper 48. Thechassis 44 may be molded from a material such as plastic as a unitaryelement that includes a plurality of preformed wells, recesses, andstructural members for, inter olio, mounting or integrating elements ofthe various subsystems that operate the robotic device 40. Suchsubsystems may include a microprocessor, a power subsystem (includingone or more power sources for the various subsystems and components), amotive subsystem, a sensor subsystem, and task-specific componentsubsystems. The cover 46 may be molded from a material such as plasticas a unitary element that is complementary in configuration with thechassis 44 and provides protection of and access to elements andcomponents mounted to the chassis 44. The chassis 44 and the cover 46are detachably integrated in combination by any suitable means (e.g.,screws), and in combination, the chassis 44 and cover 46 form astructural envelope of minimal height having a generally cylindricalconfiguration that is generally symmetrical along the fore-aft axis FA.

The displaceable bumper 48, which has a generally arcuate configuration,is mounted in movable combination at the forward portion of the chassis44 to extend outwardly therefrom (the “normal operating position”). Themounting configuration of the displaceable bumper 48 is such that it isdisplaced towards the chassis 44 (from the normal operating position)whenever the bumper 48 encounters a stationary object or obstacle ofpredetermined mass (the “displaced position”), and returns to the normaloperating position when contact with the stationary object or obstacleis terminated (due to operation of a control sequence which, in responseto any such displacement of the bumper 48, implements a “bounce” modethat causes the robot 40 to evade the stationary object or obstacle andcontinue its task routine).

Mounted on the robotic device 40 are a pair of detectors 50, 52. In thisembodiment of the robotic device 40, the detectors 50, 52 receivesignals projected from the emitters 18, 20 on the base station 10. Inother embodiments, a single detector receives signals from both emitters18, 20 on the base station 10, or more than two detectors may be used.In certain embodiments, the detectors 50, 52 are standard infrared(“IR”) detector modules, that include a photodiode and relatedamplification and detection circuitry, in conjunction with anomni-directional lens, where omni-directional refers to a substantiallysingle plane. The IR detector module can be of the type manufactured byEast Dynamic Corporation (p/n IRM-8601S). However, any detector,regardless of modulation or peak detection wavelength, can be used aslong as the emitters 18, 20 on the base station 10 are adapted to matchthe detectors 50, 52 on the robot 40. In another embodiment, IRphototransistors may be used with or without electronic amplificationelements and may be connected directly to the analog inputs of amicroprocessor. Signal processing tray then be used to measure theintensity of IR light at the robot 40, which provides an estimate of thedistance between the robot 40 and the source of IR light. Alternatively,radio frequencies, magnetic fields, and ultrasonic sensors andtransducers may be employed. As shown in FIGS. 2A-2B, at least onedetector 50 is mounted at the highest point on the robot 40 and towardthe front of the robot 40 as defined by the primary traveling direction,as indicated by an arrow on axis FA.

While the detector 50 is mounted at the highest point of the robot 40 inorder to avoid shadows, it is desirable in certain applications tominimize the height of the robot 40 and/or the detector 50 to preventoperational difficulties and to allow the robot 40 to pass underobstacles. In certain embodiments, the detector 50 can be spring-mountedto allow the detector 50 to collapse into the body of the robot 40 whenthe robot 40 runs under a solid overhanging object.

One of skill in the art will recognize that, in alternative embodiments,multiple detectors can be used. Such an embodiment might include usingmultiple side-mounted sensors or detectors. Each of the sensors can beoriented in a manner so that a collective field of view of all thesensors corresponds to that of the single, top mounted sensor. Because asingle, omni-directional detector is mounted at the highest point of therobot for optimal performance, it is possible to lower the profile ofthe robot by incorporating multiple, side mounted detectors.

The undercarriage of the robotic device 40 is indicated generally bynumeral 54. One or more charging contacts are present in theundercarriage 54, configured in such a location to correspond with thelocation of the electrical contacts. 16 of the base station 10.Generally, the charging contacts on the robotic device mirror thosepresent on the base station 10, regardless of their location ororientation. In certain embodiments, the charging contacts may be largeron either the base station 10 or robot 40, to allow wider compliance inmaking contact. Also, the motive and task specific components of therobot 40 are located in the undercarriage 54. The motive components mayinclude any combination of motors, wheels, drive shafts, or tracks asdesired, based on cost or intended application of the robot 40, all ofwhich are well known in the art. The motive components may include atleast one caster 56 which, in this embodiment, drives the robot 40 andmates with the depression 26 on the base plate 12. As the tasks to whichthe robotic device 40 is suited are virtually unlimited, so too are thecomponents to perform those tasks. For example, the robotic device 40may be used for floor waxing and polishing, floor scrubbing, iceresurfacing (as typically performed by equipment manufactured under thebrand name Zamboni®), sweeping and vacuuming, unfinished floor sandingand stain/paint application, ice melting and snow removal, grasscutting, etc. Any number of components may be required for such tasks,and may each be incorporated into the robotic device 40, as necessary.For simplicity, this application will describe vacuuming as thedemonstrative predetermined task. It will be apparent, though, that theenergy management and auto-docking functions disclosed herein have wideapplication across a variety of robotic systems.

The robotic device 40 uses a variety of behavioral modes to vacuumeffectively a working area. Behavioral modes are layers of controlsystems that can be operated in parallel. The microprocessor isoperative to execute a prioritized arbitration scheme to identify andimplement one or more dominant behavioral modes for any given scenario,based upon inputs from the sensor system. The microprocessor is alsooperative to coordinate avoidance, homing, and docking maneuvers withthe base station 10.

Generally, the behavioral modes for the described robotic device 40 canbe characterized as: (1) coverage behavioral modes; (2) escapebehavioral modes, and (3) safety behavioral modes. Coverage behavioralmodes are primarily designed to allow the robotic device 40 to performits operations in an efficient and effective manner, while the escapeand safety behavioral modes are priority behavioral modes implementedwhen a signal from the sensor system indicates that normal operation ofthe robotic device 40 is impaired (e.g., obstacle encountered), or islikely to be impaired (e.g., drop-off detected).

Representative and illustrative coverage behavioral modes (forvacuuming) for the robotic device 40 include: (1) a Spot Coveragepattern; (2) an Obstacle-Following (or Edge-Cleaning) Coverage pattern,and (3) a Room Coverage pattern. The Spot Coverage pattern causes therobotic device 40 to clean a limited area within the defined workingarea, e.g., a high-traffic area. In a certain embodiments the SpotCoverage pattern is implemented by means of a spiral algorithm (butother types of self-bounded area algorithms, such as polygonal, can beused). The spiral algorithm, which causes outward or inward spiralingmovement of the robotic device 40, is implemented by control signalsfrom the microprocessor to the motive system to change the turnradius/radii thereof as a function of time or distance traveled (therebyincreasing/decreasing the spiral movement pattern of the robotic device40).

The robotic device 40 is operated in the Spot Coverage pattern for apredetermined or random period of time, for a predetermined or randomdistance (e.g., a maximum spiral distance) and/or until the occurrenceof a specified event, e.g., activation of one or more of the obstacledetection systems (collectively a transition condition). Once atransition condition occurs, the robotic device 40 can implement ortransition to a different behavioral mode, e.g., a Straight Linebehavioral mode (in one embodiment of the robotic device 40, theStraight Line behavioral mode is a low priority, default behavior thatpropels the robot in an approximately straight line at a preset velocityof approximately 0.306 m/s) or a Bounce behavioral mode in combinationwith a Straight Line behavioral mode. The Bounce behavioral mode is abasic function that allows the robot 40 to evade a stationary object orobstacle and continue its task routine. Avoidance is achieved byexecuting a series of turns until the obstacle is no longer detected(i.e., the bumper 48 is no longer compressed).

If the transition condition is the result of the robotic device 40encountering an obstacle, the robotic device 40 can take other actionsin lieu of transitioning to a different behavioral mode. The roboticdevice 40 can momentarily implement a behavioral mode to avoid or escapethe obstacle and resume operation under control of the spiral algorithm(i.e., continue spiraling in the same direction). Alternatively, therobotic device 40 can momentarily implement a behavioral mode to avoidor escape the obstacle and resume operation under control of the spiralalgorithm (but in the opposite direction—reflective spiraling).

The Obstacle-Following Coverage pattern causes the robotic device 40 toclean the perimeter of the defined working area, e.g., a room bounded bywalls, and/or the perimeter of an obstacle (e.g., furniture) within thedefined working area. Preferably, the robotic device 40 utilizes anobstacle-following system to continuously maintain its position withrespect to an obstacle, such as a wall or a piece of furniture, so thatthe motion of the robotic device 40 causes it to travel adjacent to andconcomitantly clean along the perimeter of the obstacle. Differentembodiments of the obstacle-following system can be used to implementthe Obstacle-Following behavioral pattern.

In certain embodiments, the obstacle-following system is operated todetect the presence or absence of the obstacle. In an alternativeembodiment, the obstacle-following system is operated to detect anobstacle and then maintain a predetermined distance between the obstacleand the robotic device 40. In the first embodiment, the microprocessoris operative, in response to signals from the obstacle-following system,to implement small clockwise or counterclockwise turns to maintain itsposition with respect to the obstacle. The robotic device 40 implementsa small clockwise turn when the robotic device 40 transitions fromobstacle detection to non-detection (reflection to non-reflection) or toimplement a small counterclockwise turn when the robotic device 40transitions from non-detection to detection (non-reflection toreflection). Similar turning behaviors are implemented by the roboticdevice 40 to maintain the predetermined distance from the obstacle.

The robotic device 40 is operated in the Obstacle-Following behavioralmode for a predetermined or random period of time, for a predeterminedor random distance (e.g., a maximum or minimum distance) and/or untilthe occurrence of a specified event, e.g., activation of one or more ofthe obstacle detection system a predetermined number of times(collectively a transition condition). In certain embodiments, themicroprocessor will cause the robotic device 40 to implement an Alignbehavioral mode upon activation of the obstacle-detection system in theObstacle-Following behavioral mode, wherein the robot 40 implements aminimum angle counterclockwise turn to align the robotic device 40 withthe obstacle.

The Room Coverage pattern can be used by the robotic device 40 to cleanany defined working area that is bounded by walls, stairs, obstacles orother barriers (e.g., a virtual wall unit that prevents the roboticdevice 40 from passing through an otherwise unbounded zone). Certainembodiments of the Room Coverage pattern include the Random-Bouncebehavioral mode in combination with the Straight Line behavioral mode.Initially, the robotic device 40 travels under control of theStraight-Line behavioral mode (wheels operating at the same rotationalspeed in the same direction) until an obstacle is encountered. Theobstacle may be indicated by physical contact with a wall or detectionof the base station avoidance signal. Upon activation of one or more ofthe obstacle detection system, the microprocessor is operative tocompute an acceptable range of new directions based upon the obstacledetection system activated. The microprocessor selects a new headingfrom within the acceptable range and implements a clockwise orcounterclockwise turn to achieve the new heading with minimal movement.In some embodiments, the new turn heading may be followed by forwardmovement to increase the cleaning efficiency of the robotic device 40.The new heading may be randomly selected across the acceptable range ofheadings, or based upon some statistical selection scheme, such asGaussian distribution. In other embodiments of the Room. Coveragebehavioral mode, the microprocessing unit can be programmed to changeheadings randomly or at predetermined times, without input from thesensor system.

The robotic device 40 is operated in the Room Coverage behavioral modefor a predetermined or random period of time, for a predetermined orrandom distance (e.g., a maximum or minimum distance) and/or until theoccurrence of a specified event, e.g., activation of theobstacle-detection system a predetermined number of times (collectivelya transition condition).

Certain embodiments of the robotic device 40 include four escapebehavioral modes: a Turn behavioral mode, an Edge behavioral mode, aWheel Drop behavioral mode, and a Slow behavioral mode. One skilled inthe art will appreciate that other behavioral modes can be utilized bythe robotic device 40. One or more of these behavioral modes may beimplemented, for example, in response to a current rise in one of thetask components (indicating some sort of interference), the forwardbumper 48 being in compressed position for determined time period, ordetection of a wheel-drop event.

In the Turn behavioral mode, the robotic device 40 turns in place in arandom direction, starting at higher velocity (e.g., twice normalturning velocity) and decreasing to a lower velocity (one-half normalturning velocity), i.e., small panic turns and large panic turns,respectively. Low panic turns are preferably in the range of 45° to 90°,large panic turns are preferably in the range of 90° to 270°. The Turnbehavioral mode prevents the robotic device 40 from becoming stuck onsurface impediments (e.g., high spot on carpet), from becoming stuckunder other obstacles (e.g., an overhang), or from becoming trapped in aconfined area.

In the Edge behavioral mode, the robotic device 40 follows the edge ofan obstacle unit it has turned through a predetermined number ofdegrees, without activation of any of the obstacle detection units, oruntil the robotic device 40 has turned through a predetermined number ofdegrees, since initiation of the Edge behavioral mode. The Edgebehavioral mode allows the robotic device 40 to move through thesmallest possible openings to escape from confined areas.

In the Wheel Drop behavioral mode, the microprocessor reverses thedirection of the main wheel drive assemblies momentarily, then stopsthem. If the activated wheel drop sensor deactivates within apredetermined time, the microprocessor then reimplements the behavioralmode that was being executed prior to the activation of the wheel dropsensor.

In response to certain events, e.g., activation of a wheel drop sensoror a cliff detector, the Slow behavioral mode is implemented to slowdown the robotic device 40 for a predetermined distance and then rampback up to its normal operating speed.

When a safety condition is detected by the sensor subsystem, e.g., aseries of task component or wheel stalls that cause the correspondingelectric motors to be temporarily cycled off, or a wheel drop sensor ora cliff detection sensor activated for greater that a predeterminedperiod of time, the robotic device 40 is generally cycled to an offstate. In addition, an audible alarm may be generated.

The foregoing description of typical behavioral modes for the roboticdevice 40 are intended to be representative of the types of operatingmodes that can be implemented by the robotic device 40. One skilled inthe art will appreciate that the behavioral modes described above can beimplemented in other combinations and other modes can be defined toachieve a desired result in a particular application.

A navigational control system may be used advantageously in combinationwith the robotic device 40 to enhance the cleaning efficiency thereof,by adding a deterministic component (in the form of a control signalthat controls the movement of the robotic device 40) to the motionalgorithms, including random motion, autonomously implemented by therobotic device 40. The navigational control system operates under thedirection of a navigation control algorithm. The navigation controlalgorithm includes a definition of a predetermined triggering event.

Broadly described, the navigational control system, under the directionof the navigation control algorithm, monitors the movement activity ofthe robotic device 40. In one embodiment, the monitored movementactivity is defined in terms of the “position history” of the roboticdevice 40, as described in further detail below. In another embodiment,the monitored movement activity is defined in terms of the“instantaneous position” of the robotic device 40.

The predetermined triggering event is a specific occurrence or conditionin the movement activity of the robotic device 40. Upon the realizationof the predetermined triggering event, the navigational control systemoperates to generate and communicate a control signal to the roboticdevice 40. In response to the control signal, the robotic device 40operates to implement or execute a conduct prescribed by the controlsignal, i.e., the prescribed conduct. This prescribed conduct representsa deterministic component of the movement activity of the robotic device40.

While the robotic device 40 is vacuuming, it will periodically approachthe stationary base station 10. Contact with the base station 10 coulddamage or move the base station into an area that would make dockingimpossible. Therefore, avoidance functionality is desirable. To avoidinadvertent contact, the base station 10 may generate an avoidancesignal 60, as depicted in FIG. 3. The avoidance signal 60 is shown beingtransmitted from the emitter 18 on the top of the backstop 14. Theradial range of the avoidance signal 60 from the base station 10 mayvary, depending on predefined factory settings, user settings, or otherconsiderations. At a minimum, the avoidance signal 60 need only projecta distance sufficient to protect the base station 10 from unintentionalcontact with the robot 40. The avoidance signal 60 range can extend frombeyond the periphery of the base station 10, to up to and beyond severalfeet from the base station 10, depending on the application.

Here, the avoidance signal 60 is depicted as an omni-directional (i.e.,single plane) infrared beam, although other signals are contemplated,such as a plurality of single stationary beams or signals. If stationarybeams are used, however, a sufficient number could provide adequatecoverage around the base station 10 to increase the chances of therobotic device 40 encountering them. When the detector 50 of the roboticdevice 40 receives the avoidance signal 60 from the emitter 18, therobotic device 40 can alter its course, as required, to avoid the basestation 10. Alternatively, if the robotic device 40 is actively orpassively seeking the base station 10 (for recharging or other dockingpurposes), it can alter its course toward the base station 10, such asby circling the base station 10, in such a way to increase the chancesof encountering the homing signals described with respect to FIGS. 4A-48below.

In certain embodiments, a collimated IR emitter is used, such asWaitrony p/n IE-320H. Because of potential interference from sunlightand other IR sources, most IR devices, such as remote controls, personaldigital assistants and other IR communication devices, emit signals thatmay be modulated. Herein, the emitters 18, 20 modulate the beams at 38kHz. In an embodiment of the present invention, additional modulation ofthe beams at a frequency, for example 500 Hz, different from thefrequency of common IR bit streams, prevents interference with other IRequipment. Generally, the avoidance signal 60 is coded, as are thehoming signals 62, 64. The bit encoding method as well as binary codesare selected such that the robot 40 can detect the presence of eachsignal, even if the robot 40 receives multiple codes simultaneously.

Whenever measurable level of IR radiation from the avoidance signal 60strikes the detector 50, the robot's IR avoidance behavior is triggered.In one embodiment, this behavior causes the robot 40 to spin in place tothe left until the IR signal falls below detectable levels. The robot 40then resumes its previous motion. Spinning left is desired in certainsystems because, by convention, the robot may attempt to keep allobjects to its right during following operations. The robot's avoidancebehavior is consistent with its other behaviors if it spins left ondetecting the avoidance signal 60. In one embodiment, the detector 50acts as a gradient detector. When the robot 40 encounters a region ofhigher IR intensity, the robot 40 spins in place. Because the detector50 is mounted at the front of the robot 40 and because the robot 40 doesnot move backward, the detector 50 always “sees” the increasing IRintensity before other parts of the robot 40. Thus, spinning in placecauses the detector 50 to move to a region of decreased intensity. Whenthe robot 40 next moves forward, it necessarily moves to a region ofdecreased IR intensity—away from the avoidance signal 60.

In other embodiments, the base station 10 includes multiple codedemitters at different power levels or emitters that vary their powerlevel using a system of time multiplexing. These create concentric codedsignal rings which enable the robot 40 to navigate towards the basestation 10 from far away in the room. Thus, the robot 40 would be awareof the presence of the base station 10 at all times, facilitatinglocating the base station 10, docking, determining how much of the roomhas been cleaned, etc. Alternatively, the robot 40 uses its motionthrough the IR field to measure a gradient of IR energy. When the signof the gradient is negative (i.e., the detected energy is decreasingwith motion), the robot 40 goes straight (away from the IR source). Whenthe sign of the gradient is positive (energy increasing), the robot 40turns. The net effect is to implement a “gradient descent algorithm,”with the robot 40 escaping from the source of the avoidance signal 60.This gradient method may also be used to seek the source of emittedsignals. The concentric rings at varying power levels facilitate thispossibility even without a means for determination of the raw signalstrength.

A flowchart of one embodiment of the control logic of the avoidancebehavior 100 is shown in FIG. 6A. The robot 40 determines whether thesignal 110 detected by the detector 50 is an avoidance signal 60. If anavoidance signal 60 is detected, the robot 40 chooses a turningdirection 120. The robot 40 then begins to turn in the chosen directionuntil the avoidance signal 60 is no longer detected 130. Once theavoidance signal 60 is no longer detected, the robot 40 continuesturning for an additional amount 140, such as 20°, or the robot may turnrandomly between 0° and 135°.

While in flowchart step 120, the direction selection algorithm 120 a,illustrated in the flowchart shown in FIG. 6B, is used. The robot'scontrol logic keeps track of the robot's discrete interactions with thebeam. The robot 40 first increments a counter by one 122. On oddnumbered interactions, the robot 40 chooses a new turning directionrandomly 124, 126; on even numbered interactions, the robot 40 againuses its most recent turning direction. In the alternative, the robot 40may choose which direction to turn at random. It will continue to turnin that direction until it has moved a sufficient distance.

In other embodiments, the robot 40 can always turn in a single directionor choose a direction randomly. When the robot 40 always turns in onedirection, it may get stuck in a loop by turning away from the beam,bumping into another obstacle in a room, turning back toward the beam,seeing the beam again, turning away, bumping again, ad infinitum.Moreover, when the robot 40 only turns in a single direction, itconsequently may fail to vacuum certain areas of the floor. Thus, wherethe robot's task is to complete work evenly throughout a room, a singleturning direction may not be optimal. If the direction is chosen purelyrandomly, the robot 40 may turn back and forth often, as it encountersthe beam.

Again referring to FIG. 6A, in the embodiment of step 140, the robot 40turns an additional 20° from the point at which the avoidance signal 60is lost. The arc of the turn can be varied for the particular robot 40and application. The additional turn helps to prevent the robot 40 fromre-encountering the avoidance signal 60 immediately after firstencountering it. For various applications, the amount of additionalmovement (linear or turning) can be a predetermined distance, angle ortime, or in the alternative may include a random component. In stillother embodiments, the robot's avoidance behavior may include reversingthe robot's direction until the avoidance signal 60 is no longerdetected, or as described above, the robot may turn randomly between 0°and 135° after losing the avoidance signal 60.

FIGS. 4A-4C depict the robotic device 40 in various stages of seekingthe base station 10 by using the homing signals 62, 64. The roboticdevice 40 may seek the base station 10 when it detects the need torecharge its battery, or when it has completed vacuuming the room. Asdescribed above, once the robotic device 40 detects the presence of theavoidance signal 60 (and therefore the base station 10), it can move asrequired to detect the homing signals 62, 64. As with the avoidancesignal 60 above, the projected range and orientation of the homingsignals 62, 64 may be varied, as desired. It should be noted however,that longer signals can increase the chance of the robot 40 finding thebase station 10 efficiently. Longer signals can also be useful if therobotic device 40 is deployed in a particularly large room, wherelocating the base station 10 randomly could be inordinately timeconsuming. Homing signal 62, 64 ranges that extend from approximatelysix inches beyond the front of the base plate 12, to up to and beyondseveral feet beyond the base plate 12 are contemplated, depending onapplication. Naturally, the angular width of the homing signals 62, 64may vary depending on application, but angular widths in the range of 5°to up to and beyond 60° are contemplated. A gradient behavior asdescribed above can also be used to aid the robot in seeking out thebase station.

In addition to operating as navigational beacons, horning signals 62, 64(and even the avoidance signal 60) may also be used to transmitinformation, including programming data, fail safe and diagnosticinformation, docking control data and information, maintenance andcontrol sequences, etc. In such an embodiment, the signals can providethe control information, dictating the robot's reactions, as opposed tothe robot 40 taking certain actions upon contacting certain signals fromthe base station 10. In that case, the robot 40 functions as more of aslave to the base station 10, operating as directed by the signals sent.

The robot 40 performs its docking with the base station 10 accuratelyand repeatably, without the need for gross mechanical guidance features.The two homing signals 62, 64 are distinguishable by the robotic device,for example as a red signal 62 and a green signal 64. IR beams aregenerally used to produce the signals and, as such, are not visible. Thecolor distinction is given for illustrative purposes only, and any“color” (i.e., signal bit pattern) may be used, provided the roboticdevice 40 recognizes which signal to orient a particular side.Alternatively, the signals 62, 64 may be distinguished by usingdifferent wavelengths or by using different carrier frequencies (e.g.,380 kHz versus 38 kHz, etc.).

Thus, when the robotic device 40 wants or needs to dock, if the detector50 receives the red signal 62 transmitting from the base station 10, itmoves to keep the red signal 62 on the robot's right side; if it detectsthe green signal 64 transmitting from the base station 10, it moves tokeep the green signal 64 on the robot's left side. Where the two signalsoverlap (the “yellow” zone 66), the robot 40 knows that the base station10 is nearby and may then dock. Such a system may be optimized to makethe yellow zone 66 as thin as practicably possible, to ensure properorientation and approach of the robot 40 and successful docking.Alternatively, the red signal 62 and green signal 64 may be replaced bya single signal, which the robot 40 would follow until docked.

FIGS. 4A-4C depict, at various stages, a docking procedure utilizing twosignals. In FIG. 4A, the detector 50 is in the green or left signal 64field, and thus the robotic device 40 will move towards the right, indirection M_(R) in an effort to keep that green signal 64 to the left ofthe robot 40 (in actuality, the robot 40 moves to keep the green signal64 to the left of the detector 50). Similarly, in FIG. 4B, the detector50 is in the red or right signal 62 field, and thus the robotic device40 will move towards the left, in direction M_(L) in an effort to keepthat red signal 64 to the right of the detector 50. Last, in FIG. 4C,the detector 50 has encountered yellow zone 66. At this point, therobotic device 40 will move in direction M_(F) directly towards the basestation 10. While approaching the base station 10, the robotic device 40may slow its speed of approach and/or discontinue vacuuming, or performother functions to ensure trouble-free docking. These operations mayoccur when the robot 40 detects the avoidance signal 60, thusrecognizing that it is close to the base station 10, or at some otherpredetermined time, e.g., upon a change in the signal from the emitters62, 64.

Various methods are contemplated for ensuring that the robot 4Qcorrectly docks with base station 10. For example, the robot 40 cancontinue to move toward the base station 10 (within the yellow zone 66)until the bumper 48 is depressed, signaling the robot 40 that it hascontacted the base station 10. Another embodiment overlaps the horningsignals 62, 64 such that the yellow zone 66 terminates at a pointcalibrated such that the robot 40 will contact the charging contacts 16upon reaching the termination point. Other embodiments simply stop therobot 40 when its electrical contacts touch the electrical contacts 16on the base station 10. This would guarantee that the robot 40 is movingover the contacts 16, providing a wiping action that cleans the contacts16 and improves the electrical integrity of the connection. This alsoenables the base station 10 to be lighter, since it does not have toresist the force necessary to depress the robot's bumper 48. FIG. 5shows the robotic device 40 completely docked with the base station 10.Naturally, this procedure may also utilize detector 52 or a combinationof both detectors.

While this embodiment of the invention describes use of IR signals forboth avoidance and homing, the system and method of the presentinvention can use other signals to accomplish the goals. Other types ofwaves may have drawbacks, however. For example, radio waves are moredifficult and expensive to make directional, and visible light suffersfrom interference from many sources and may be distracting to users.Sound waves could also be used, but it is similarly difficult to makesound purely directional and such waves tend to scatter and reflectmore.

FIG. 7 depicts a schematic diagram which shows the control sequence 200of the robotic device 40 during vacuuming. Generally, the controlsequence 200 includes three subsequences based on the measured energylevel of the robotic device 40. Those are referenced generally as a highenergy level 210, a medium energy level 220, and a low energy level 230.In the high energy level subsequence 210, the robotic device 40 performsits predetermined task, in this case, vacuuming (utilizing variousbehavioral modes as described above), while avoiding the base station212. When avoiding the base station 212, the robotic device 40 performsits avoidance behavior and continues to operate normally. This processcontinues while the robotic device 40 continually monitors its energylevel 214. Various methods are available to monitor the energy level 214of the power source, such as coulometry (i.e., the measuring of currentconstantly entering and leaving the power source), or simply measuringvoltage remaining in the power source. Other embodiments of the roboticdevice 40 may simply employ a timer and a look-up table stored in memoryto determine how long the robotic device 40 can operate before it entersa different energy level subsequence. Still other embodiments may simplyoperate the robot 40 for a predetermined time period before recharging,without determining which energy level subsequence it is operating in.If the robot 40 operates on a liquid or gaseous fuel, this level mayalso be measured with devices currently known in the art.

Once the energy remaining drops below a predetermined high level, therobot 40 enters its medium energy level sequence 220. The robot 40continues to vacuum and monitor its energy level 224, employing methodsindicated in step 214 above. In the medium energy level 220, however,the robot 40 “passively seeks” 222 the base station 10. While passivelyseeking 222 the base station 10, the robot 40 does not alter its travelcharacteristics; rather, it continues about its normal behavioral modeuntil it fortuitously detects the avoidance signal 60 or a homing signal62, 64, each of which tray be followed until the robot 40 ultimatelydocks with the base station 10. In other words, if the robot detects theavoidance signal 60 while passively seeking 222, rather than avoidingthe base station 10 as it normally would, it alters its travelcharacteristics until it detects the homing signals 62 or 64, thusallowing it to dock.

Alternatively, the robot 40 continues operating in this medium energylevel subsequence 220 until it registers an energy level 224 below apredetermined low level. At this point, the robot 40 enters the lowlevel subsequence 230, characterized by a change in operation and travelcharacteristics. To conserve energy, the robot 40 may discontinuepowering all incidental systems, and operations, such as vacuuming,allowing it to conserve as much energy as possible for “activelysearching” 232 for the base station 10. While actively searching 232,the robot 40 may alter its travel characteristics to increase itschances of finding the base station 10. It may discontinue behavioralmodes such as those employing a spiral movement, which do notnecessarily create a higher chance of locating the base station, infavor of more deliberate modes, such as wall-following. This deliberateseeking will continue until the robot 40 detects the presence of thebase station 10, either by detecting the avoidance signal 60 or thehoming signals 62, 64. Clearly, additional subsequences may beincorporated which sound alarms when the power remaining reaches acritical level, or which reconstruct the route the robot 40 has takensince last contacting the base station 10 to aid in relocating thestation 10.

The robot 40 may also dock because it has determined that it hascompleted its assigned task (e.g., vacuuming a room). The robot 40 maymake this determination based on a variety of factors, includingconsiderations regarding room size, total run time, total distancetraveled, dirt sensing, etc. Alternatively, the robot may employroom-mapping programs, using the base station 10 and/or walls and largeobjects as points of reference. Upon determining that it has completedits task, the robot 40 will alter its travel characteristics in order tofind the base station 10 quickly.

Once the robot 40 contacts the base station 10, it can recharge itselfautonomously. Circuitry within the base station 10 detects the presenceof the robot 40 and then switches on the charging voltage to itscontacts 16. The robot 40 then detects the presence of the chargingvoltage and then switches on its internal transistor power switch toallow current flow into the battery. In one embodiment, the base station10 contains a constant-current type switching charger. Maximum currentis limited to approximately 1.25 amps even under a short circuitcondition. Maximum unloaded terminal voltage is limited to approximately22Vdc. This constant-current charging circuit is used to charge thebattery in the robot 40 via the electrical connections provided by thecontacts 16 on the base station 10 and those on the undercarriage 54 ofthe robot 40. One embodiment of this charging sequence is detailedbelow.

Generally, while the robot 40 is away from the base station 10, thecharging contacts 16 will present five volts, limited to 1 mA maximumshort circuit current flow. This low voltage/low current “sense”condition limits the amount of available energy at the contacts 16, thusrendering them safe in the event they are contacted by humans, animals,and electrically conductive objects. The contacts on the undercarriage54 of the robot 40, when contacting the contacts 16 on the base station10, present a precise resistive load that, along with a resistor in thebase station 10, creates a high impedance voltage divider. Amicroprocessor that constantly monitors the voltage across the contacts16 recognizes this lower voltage. This voltage divider creates aspecific voltage, plus or minus a known tolerance. When themicroprocessor determines that the voltage has fallen into the specificrange, it detects that the robot 40 is present. The microprocessor thenturns on a transistor switch that delivers a higher voltage/currentcharge (capable of charging the robot's internal battery) to thecharging contacts 16. Alternatively, the robot 40 and/or base station 10can verify the integrity of the charging circuit by sending signalsthrough the IR beams, thereby confirming that the robot 40 has, in fact,docked.

FIG. 8 depicts an embodiment of the charger circuitry schematic. Withfive volts being presented by the base station, it is the job ofresistor dividers R101 and R116 to hold Q48 and Q5 off when J25 is incontact with the initial low voltage state. This divider also providesthe known impedance of R101 plus R116 in parallel with R224 plus thebase-emitter diode drop of Q48. This Thevenin impedance is in serieswith a resistor in the docking station thus forming a voltage divider. Awindow comparator circuit within the docking station looks for aspecific voltage created by the divider. Once the base station hasdetermined this impedance is likely the robot (not some other conductivebody), it then delivers the full 22 volt capable, 1.25 Amp chargingvoltage to the robot.

At the onset of this higher voltage, the divider of R101 and R224 aresuch that the requirements are met to turn on Q48 and Q5 respectively.It is this combination of transistors that then allows current to flowto the on-board robot electronics only, allowing the robot's processorto become active if in fact it was inoperative due to a depletedbattery.

Once operative, the robot's processor is then able to detect thepresence of the base station voltage via R113 and D15 and if driving,turn off its drive motors. Once stable on the charging contacts, itbecomes the job of the robot processor to measure the internal robotbattery and decide when and what type of charging control cycle isneeded when allowing current to flow into the battery. For example, ifthe battery is at 12 volts, then it is acceptable to turn on Q45 and Q47via processor control, in order to allow current to flow through FET U9to the battery on a continuous basis.

If, however, the battery voltage is deemed less than 5 volts, itgenerally would not be desirable to allow the full current to flow tothe battery on a continuous basis. The reason this condition is ofconcern lies in the fact that the power source within the DOC is aconstant current charger, which will adjust its output voltage to beslightly higher than the battery voltage in order to flow 1.25 A intothe battery. In some cases, this might be millivolts higher than thebattery voltage itself and in the case of the battery at low voltage,for example, 3 volts, would cause the output voltage to drop below thenecessary 5 volt level needed to operate the on board base station androbot electronics suite.

In this case, the robot processor then delivers a pulse width modulationto the charger control line pertaining to Q47, such that the energystorage capacitors in both the robot and base station maintain enoughcharge to keep their respective electronics working properly throughoutthe charge pulse. The energy storage capacitors are then replenishedduring the off time of the pulse width modulation charging cycle, readyto then sustain the next charge pulse. This scenario continues until thebattery has been charged to the point where a continuous charge is nolonger able to bring the supply voltage down to a critical level and thecharge control can become a static level.

Since this pulse width modulation process in this embodiment relies onsoftware control, health monitoring of the processor, both within thebase station and robot, are important. The requirement then set fourthfor charging is for a charger “watchdog” be incorporated via Q45 suchthat a static high or low state on this signal line will disable currentflow into the battery. It is a requirement of the robot processor tocontinuously pulse this control line in order for any current to flow,therefore eliminating most cases of processor latch up due toelectrostatic discharge or other battery related events from mistreatingthe charging profile. Naturally, other control and related fail safeschemes could be utilized.

The described charging sequence provides particular safety features,even though the charging contacts 16 are exposed and energized. Becausea specific resistance required to create a specific voltage drop acrossthe contacts 16 when the 5-volt sense voltage is present (i.e., when therobot 40 is not docked) there is no danger of electric shock due toaccidental contact because the low sense current is harmless. Also, thebase station 10 will never switch to the higher voltage/current level,because the sense current has not entered the predetermined range. Whenthe base station 10 does determine that the robot 40 is present, itdelivers the charging voltage/current. This charging current is limitedto approximately 22 volts/1.25 amps maximum. Even if inadvertent contactoccurred during delivery of the charging current—which is unlikely,since the robot chassis 44 effectively blocks the contacts 16—thevoltage delivered would not present a serious shock hazard, as it isrelatively low.

Another level of safety is afforded by the base station 10 checking forthe robot 40 at regular intervals, from as little as once per minute toas much as 10 times per second or more. Thus, in the event that therobot 40 is dislodged from the base station 10 (either by an animal orhuman), the charging current could be shut down immediately. This samecondition applies if the contacts 16 are short circuited with the robot40 docked (either intentionally or accidentally, for example, if therobot 40 drags debris onto the charging contacts 16).

An additional safety feature of this charging sequence preventsoverheating of contacts 16 due to intentional shorting or oxidation. Athermal circuit breaker or similar device can be employed to performthis task, as well as a microprocessor equipped with a temperaturemeasuring subroutine. The circuit breaker, however, provides theadvantage of controlling contact temperature in the event of amicroprocessor or software failure. Additionally, the base station 10circuitry can also incorporate a timer to reset the temperaturemeasuring subroutine or circuit breaker in the event of system failure.These safety controls may be incorporated into the “watchdog” describedabove.

While docked with the base station 10, the robot 40 can also performother maintenance or diagnostic checks. In certain embodiments, therobot 40 can completely recharge its power source or only partiallycharge it, based on various factors. For example, if the robot 40determines, through the use of route-tracking subroutines, that only asmall portion of the room still requires vacuuming, it may take only aminimal charge before returning to complete cleaning of the room. If,however, the robot 40 requires a full charge before returning to cleanthe room, that option is also available. If the robot 40 has completedits vacuuming of the room prior to docking, it may dock, fully recharge,and stand by to await a signal (either internal or external) to beginits next cleaning cycle. While in this stand-by mode, the robot 40 maycontinue to measure its energy levels and may begin charging sequencesupon reaching an energy level below a predetermined amount.Alternatively, the robot 40 may maintain a constant or near-constanttrickle charge to keep its energy levels at or near peak. Otherbehaviors while in the docking position such as diagnostic functions,internal mechanism cleaning, communication with network, or datamanipulation functions may also be performed.

While there have been described herein what are to be consideredexemplary and preferred embodiments of the present invention, othermodifications of the invention will become apparent to those skilled inthe art from the teachings herein. The particular methods of manufactureand geometries disclosed herein are exemplary in nature and are not tobe considered limiting. It is therefore desired to be secured in theappended claims all such modifications as fall within the spirit andscope of the invention. Accordingly, what is desired to be secured byLetters Patent is the invention as defined and differentiated in thefollowing claims.

What is claimed is:
 1. An autonomous cleaning robot, comprising: anundercarriage; a motive system configured to propel the undercarriageacross a ground surface; an energy storage unit supported by theundercarriage and configured to be charged while the robot is positionedat a base charging station; and a navigational control system configuredto autonomously: control the motive system to direct the robot about aroom, while mapping the room with respect to objects as points ofreference; return the robot to the base charging station beforecompleting a cleaning task in the room, in response to detecting a needto recharge the energy storage unit; dock the robot to the base chargingstation upon return; recharge the energy storage unit with the robotdocked; and then to control the motive system to direct the robot tocontinue to clean the room.
 2. The autonomous cleaning robot of claim 1,wherein the control system is configured to track a cleaning route ofthe robot and monitor an amount of the room remaining to be cleaned. 3.The autonomous cleaning robot of claim 1, wherein the control system isconfigured to use a known position of the base charging station as apoint of reference in mapping the room.
 4. The autonomous cleaning robotof claim 1, wherein the control system is configured to determine,through use of route-tracking subroutines while controlling the motivesystem to direct the robot about the room, which portion of the roomstill requires cleaning.
 5. The autonomous cleaning robot of claim 4,wherein the control system is configured to direct the robot to theportion of the room still requiring cleaning, following recharging theenergy storage unit.
 6. The autonomous cleaning robot of claim 1,wherein the robot is configured to control charging at the base chargingstation by only partially charging the energy storage unit beforeleaving the base charging station to continue cleaning the room.
 7. Theautonomous cleaning robot of claim 6, wherein the robot is configured toleave the base charging station and continue to clean the room upondetermining that the energy storage unit has reached a minimum amount ofstored energy necessary to complete the cleaning task in the room. 8.The autonomous cleaning robot of claim 1, wherein the control system isconfigured to return the robot to the base charging station beforecompleting the cleaning task in the room, in response to a quantity ofenergy remaining in the energy storage unit falling to a predeterminedthreshold.
 9. The autonomous cleaning robot of claim 8, wherein thenavigational control system is configured to direct the robot to thebase charging station by seeking a base station homing signal.
 10. Theautonomous cleaning robot of claim 8, wherein the robot is configured todetermine the quantity of energy in the energy storage unit using atleast one of coulometry and operating time.
 11. The autonomous cleaningrobot of claim 1, wherein the robot is configured to disable a cleaningfunction while returning to the base charging station.
 12. Theautonomous cleaning robot of claim 1, wherein the energy storage unitcomprises a battery.
 13. The autonomous cleaning robot of claim 1,wherein the energy storage unit comprises electrical contacts arrangedto automatically make electrical contact with the base charging stationupon docking of the robot.